Modular Floor Panel Assembly for Sustainable Net Zero Construction

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Solution Overview

Problem

Conventional construction methods are complex, time-consuming, and labor-intensive, involving multiple components manufactured separately and assembled on-site, leading to inconsistent quality, long construction timelines, and environmental impact due to materials like plastics and calcium sulfate dihydrate.

Innovation Solution

A modular construction system where all components, including plumbing, electrical, and HVAC systems, are prefabricated and assembled into floor panels, which are then connected on-site using standardized couplers, creating a self-sufficient, environmentally friendly structure with integrated smart home technologies and recyclable materials.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If conventional construction methods are used with separate component manufacturing and on-site assembly, then flexibility in customization is improved, but construction time and labor intensity increase significantly

Engineering Contradiction:

Improvecustomization flexibilityVSAvoidconstruction speed

Core Design Contradiction:

Adaptability or versatilityVSProductivity

Solution Approach 1:

The building is divided into modular floor panels that are pre-assembled in factories and then rapidly connected on-site. Each floor panel is a self-contained module containing integrated systems, allowing parallel production of multiple modules while maintaining customization through configuration selection.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

All components including plumbing, electrical, and HVAC systems are pre-installed and pre-tested in factory settings before the modules are shipped to the construction site. This preliminary assembly and quality control eliminates time-consuming on-site installation and debugging work.

Inventive Principle:

Principle #10Preliminary action

2Ease of manufacture

If conventional construction methods are used with multiple separate systems, then system independence and ease of installation are improved, but overall system integration quality and consistency deteriorate

Engineering Contradiction:

Improvesystem installation easeVSAvoidintegration quality consistency

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

Multiple separate systems (plumbing, electrical, HVAC, structural) are merged into integrated floor panel assemblies. This consolidation ensures that all systems are pre-coordinated and tested together in the factory, guaranteeing consistent integration quality while maintaining the functional independence of each system.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The integrated floor panels are designed to be self-contained units with all necessary connections and systems pre-configured. This self-service design reduces the need for complex on-site coordination and ensures consistent quality through factory-controlled assembly processes.

Inventive Principle:

Principle #25Self-service

3Adaptability or versatility

If conventional construction methods are used with extensive on-site labor, then adaptability to site conditions is improved, but labor costs and construction duration increase

Engineering Contradiction:

Improvesite condition adaptabilityVSAvoidconstruction duration

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The construction approach transitions from extensive on-site assembly to rapid module connection. The modular design allows standardization of connection parameters and interfaces, reducing the time and skill required for on-site work while maintaining adaptability through module configuration selection.

Inventive Principle:

Principle #35Parameter changes

4Ease of manufacture

If conventional construction methods are used with traditional materials, then material availability and ease of construction are improved, but environmental impact and health concerns increase

Engineering Contradiction:

Improveconstruction simplicityVSAvoidenvironmental pollution

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

The floor panels utilize composite construction combining steel frames with various panel materials, allowing selection of environmentally friendly options while maintaining structural integrity and construction efficiency. The composite approach enables integration of multiple functions (structural, insulation, finishing) in single assemblies.

Inventive Principle:

Principle #40Composite materials

Solution Approach 2:

The modular design facilitates the use of recyclable materials and enables easy disassembly and reuse of floor panels at the end of the building's life cycle. This approach reduces waste and environmental impact while maintaining construction simplicity through standardized connection systems.

Inventive Principle:

Principle #34Discarding and recovering

Data Source

PatentUS11873651B2Sustainable net zero modular building and assembly method

Publication Date: 2024.01.16 AKCHURIN INC

AI summary

Disclosed is a system and method of constructing modular homes, which are assembled from a numbered of prefabricated components and delivered as finished goods using standard containers. The modular design further provides for a self-sufficient structure where the three main engineering systems, namely, plumbing, electrical and HVAC, are completely integrated allowing the structure to maximize energy usage efficiencies. Emphasis is placed on using only environmentally friendly materials and on recycle or multi-purposing components into energy or resource gathering and production. Another emphasis is placed on speed of assembly using standardized structures that streamline on the job assembly processes.